Upright support configuration for a pallet racking system

ABSTRACT

The present invention relates to an upright reinforcing assembly for use with a pallet racking system, and racking system incorporating the same. The support configuration consists of an upright support and attached a bracket containing two L-shaped platforms which form a pocket. The upright support configuration is placed between two frame assemblies to support the beam, which is held in the pocket created by the bracket, thereby providing additional support to the beam and preventing rotation, bowing or distortion of the beam. Such a configuration lowers the cost of pallet racking as lower capacity beams can be used, or otherwise less frame assemblies are required in the racking.

FIELD OF THE INVENTION

The present invention relates to a pallet racking system and reinforcing assembly therefor. In particular, the invention relates to a system that includes intermediate supports consisting of an upright support and a bracket with a base support and upright component which, when assembled, provide support to a pallet racking beam.

BACKGROUND TO THE INVENTION

Pallet storage systems used to store cargo-carrying pallets are known. Such systems typically include a support frame for supporting the pallets and which are loadable from one or more ends of the frame. These frames are generally designed in a grid formation including upright frame assemblies and connected by beams or shelves creating levels upon which the pallets are loaded by a forklift. Typically 2 or more pallets can be accommodated between each frame assembly.

A common and known racking system is the ‘Drive-in’ system wherein the forklift is driven in between the lanes or bays of the system and the pallet is lifted into the racking. The disadvantage of this system, however, is that it is labour intensive given the care the forklift driver must take driving in and out of the racking, and is thus is also time consuming. Another disadvantage is the repair costs which are involved when errors or accidents occur with the forklifts.

‘Drive-in’ racking has thus been improved by use of the ‘Pushback’ and ‘Flowthrough’ racking alternatives, which are also known. The ‘Pushback’ system utilises a forklift to place the pallet into the racking system, whereby the pallets are then pushed back onto inclined rails inside the racking. The ‘Flowthrough’ system utilizes an incline rail with rollers and braking systems which move the pallets along a slope and wherein the pallets are loaded from one end (either the back or front of the system) and unloaded from the other end.

As pallets often contain heavy material, the horizontal cross beams in each system must be sturdy and made from a sufficiently durable material so as to adequately support the weight of several pallets.

The beams are commonly therefore made from steel or other similarly sturdy material, however use of heavy duty steel beams in pallet racking is cost prohibitive.

Cross beams made from cheaper and lighter material or beams of a lower cross-sectional amount of steel can be used and are desirable, however, the lack of strength in these beams can lead the centre of the beam to depress, distort or rotate under the pressure of the pallet weight and movement. The beam is therefore structurally weak and dangerous and cannot accommodate the desired weight of the pallets.

The object of this invention is to provide racking system including additional uprights with support brackets which alleviate some of the abovementioned problems, or at least provides the public with a useful alternative.

A further object of the invention is to provide a reinforcing assembly for use in such racking systems.

SUMMARY OF THE INVENTION

It should be noted that any one of the aspects mentioned above may include any of the features of any of the other aspects mentioned above and may include any of the features of any of the embodiments described below as appropriate.

Therefore, in one form of the invention there is proposed a pallet racking system including:

a frame assembly including a width and a depth dimension, said width dimension being defined by two outer upright frame assemblies, said frame assembly further including one or more cross beams extending horizontally between said two outer upright frame assemblies, wherein substantially aligned cross beams along the depth dimension of the racking system are adapted to support one or more pallets; at least one additional upright support adapted to be disposed on a front or rear side of said cross beam between the two outer frame assemblies, said additional upright support having at least one bracket configured to assist in supporting said cross beam.

Preferably said cross beam is of a length sufficient to accommodate two side by side and spaced apart pallets.

In preference said additional upright support and associated bracket is disposed approximately halfway between said upright frame assemblies to thereby assist in supporting a cross beam with two pallets on opposed sides of said bracket.

Preferably said bracket includes a main body configured to be secured to the additional upright support.

In preference said bracket further includes a base support surface extending outwardly from said main body to thereby support said cross beam.

In preference said additional upright support is disposed rearwards of said cross beam, and the base support surface extends forwardly from said main body.

Preferably said base support surface is horizontal.

Alternatively said base support surface includes a curvature along its length adapted to correspond with a curvature along said cross beam when pallets are supported on either side of said bracket.

Preferably said base support surface further includes rounded off edges.

Preferably said bracket further includes an upright support surface for preventing said cross beam from movement along said depth dimension relative to said additional upright support.

In preference said system includes a plurality of vertically spaced cross beams extending between each pair of spaced apart upright frame assemblies disposed along the depth dimension of the racking system.

Preferably the cross beams are substantially aligned along said depth dimension such that racked pallets are supported and moveable along the aligned cross beams.

In preference the cross beams that are substantially aligned along said depth dimension form a slight angle for facilitating movement of the racked pallets by gravity along said depth dimension.

In a further form of the invention, there is proposed a reinforcing assembly for a frame system having a frame assembly with a width and a depth dimension, said width dimension being defined by two outer upright frame assemblies, said reinforcing assembly further including one or more cross beams extending horizontally between said two outer upright frame assemblies, wherein substantially aligned cross beams along the depth dimension of the racking system are adapted to support a load, said upright support assembly including:

at least one additional upright frame member adapted to be disposed on a front or rear side of said cross beam between the two outer frame assemblies, said additional upright frame member having at least one bracket configured to assist in supporting said cross beam and load.

The skilled addressee would thus realize how the reinforcing assembly comprising the additional upright support and bracket effectively halve the span of a cross beam without requiring the addition of a new upright frame assembly and/or requiring the beam to be shortened. The present invention could thus have application in a number of different structural systems and not necessarily only in pallet racking systems.

Preferably said frame system is a pallet racking system and said load is in the form of one or more pallets.

In preference said cross beam is of a length sufficient to accommodate two side by side and spaced apart pallets.

Preferably said additional upright support and associated bracket is disposed approximately halfway between said upright frame assemblies to thereby assist in supporting a cross beam with two pallets on opposed sides of said bracket.

In preference said bracket includes a main body configured to be secured to the additional upright support.

Preferably said bracket further includes a base support surface extending outwardly from said main body to thereby support said cross beam.

In preference said additional upright support is disposed rearwards of said cross beam, and the base support surface extends forwardly from said main body.

Preferably said base support surface is horizontal.

Alternatively said base support surface includes a curvature along its length adapted to correspond with a curvature along said cross beam when pallets are supported on either side of said bracket.

Preferably said base support surface further includes rounded off edges.

In preference said bracket further includes an upright support surface for preventing said cross beam from movement along said depth dimension relative to said additional upright support.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings:

FIG. 1 is a perspective view of a pallet racking system incorporating traditional upright side frame assemblies and horizontal beams, the system including additional upright supports in accordance with the present invention;

FIG. 2 is a perspective view of a bracket according to a first embodiment of the present invention including, in an exploded view, upper and lower L-shaped platforms associated therewith which support the beam;

FIG. 3 is a perspective view of the bracket of FIG. 2 with the upper platform secured to the lower platform to create a pocket to support the beam; and

FIG. 4 is a perspective view of one of the additional upright supports shown in FIG. 1 including the bracket of FIGS. 2-3 secured thereto and supporting a horizontal cross beam; and

FIG. 5 is a perspective view of a pallet racking system including two traditional upright side frame assemblies with additional upright supports disposed there between, and a cross beam support bracket associated with each additional support configured in accordance with a second and preferred embodiment of the present invention;

FIG. 6 is an enlarged perspective view of the connector bracket of FIG. 5 in use and supporting a horizontal cross beam;

FIG. 7 is a front and side view of the connector bracket of FIG. 5 when not in use; and

FIG. 8 is a perspective view of the connector bracket of FIG. 5 when not in use.

LIST OF COMPONENTS

20 Pallet racking system

24 Beam

26 Outer upright frame

28 Centre upright frame

29 Brace

30 Additional upright support

32 Bracket

33 Bracket main body

34 Apertures

36 Lower L-shaped platform

38 Upper L-shaped platform

40 Lower platform apertures

42 Upper platform apertures

44 Pocket

46 Bolt

48 Support configuration

50 Pallet racking system (2)

52 Bracket (2)

53 Bracing (2)

54 Pocket (2)

56 Base support surface

58 L-shaped member

59 Upright portion

60 Apertures (2)

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

The following detailed description of the invention refers to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration.

The present invention relates to a pallet racking system and bracket therefor which allows for horizontal cross beams supporting the pallets to be constructed of cheaper and lighter material and/or be of lesser cross sectional size than hitherto known beams used in conventional pallet racking systems. The present invention can be used in conjunction with either the “Pushback” or “Flowthrough” racking systems which are known, but it is to be understood that the invention could equally well be applied to any kind of racking system.

Referring now to the drawings there is illustrated in FIG. 1 a racking system 20 according to the known type consisting of two outer (or side) upright frame assemblies 26 and a centre upright frame assembly 28, between which extend horizontal cross beams 24 onto which pallets (not shown) can be loaded. The system 20 includes a plurality of such frames spaced along its depth. In the embodiment shown, the front facade of the system 20 includes three upright frame assemblies 26 and 28, with five vertically spaced cross beams 24 extending between each side and central frame assembly, however the invention can be applied to alternately configured systems having two or even four or more upright frame assemblies and any number of vertically spaced cross beams.

The beams, therefore, extend between the outer frame assemblies 26 and the centre frame assembly 28, attached by known methods such as a bracket. The spacing between the outer assembly 26 and the centre assembly 28 allows for the insertion of two pallets resting comfortably next to one another (with a gap there between), and further beams 24 are attached in the same way extending the depth of the racking system. The cross beams in adjacent rows are aligned (typically on an angle as mentioned in the preamble) and thus provide a secure shelf upon which the pallets can be loaded.

Currently these cross beams, usually made from steel, need to be of a certain dimension and strength in order to support the pallets properly, however such volumes of steel are costly. It would be advantageous for the beams to be either made of a lighter material or from less steel, but still allow pallets of the same weight to be loaded into the racking system.

Lighter beams can be used, however this requires additional upright frame assemblies, usually the same as those which are used for the outer and centre assemblies, to be inserted between each of the pallets in order to provide the required support. Currently, these additional frame assemblies are more cost effective than the heavier beams, but can still be cost prohibitive. In addition, the use of shorter beams and additional frame assemblies equates to more cost for end brackets required at each end of the cross beams.

The present invention proposes the use of additional upright supports 30, rather than additional frame assemblies. These upright supports 30 are similar to the frame assemblies 26 and 28 in that they comprise one or more upright posts having spaced apart engagement apertures (not numbered for the purpose of brevity) along their height and/or width, however, because the additional support is disposed behind the cross beam and not in line with it, one beam can still be used to support two pallets between two upright assemblies. If a standard upright assembly were used instead, two beams would be required as well as two end brackets. In addition, it is envisaged that the additional supports will not require the diagonal or horizontal braces 29 which the frame assemblies use to connect and support the assemblies along the depth of the racking system. Thus, because the additional supports are effectively freestanding, much less material is required, and use of the upright supports 30 is far more cost effective than use of additional frame assemblies. In addition, because they are configured similarly to the upright support assemblies, the additional supports can be made from known and existing materials.

In a preferred embodiment of the invention, the upright support 30 is disposed halfway between each outer upright frame assembly 26 and the centre upright frame assembly 28 and thereby creates two channels on either side thereof for the insertion of two pallets. Thus, in the configuration shown in FIG. 1 for example, four pallets could be stored across the width of the racking system, that is, on two cross members which together span the width between the outer upright frame assemblies.

The upright supports extend vertically the height of the frame, as seen in FIG. 1 and are preferably attached at the rear of each of the horizontal beams 24 through use of a bracket 32 (not shown in FIG. 1). The rear positioning of the upright support 30 takes advantage of the stronger front side of the uprights and supports the rear of the cross beam. It can thus be appreciated that each additional support is effectively a vertical structure positioned at a point along a horizontal cross beam and connected thereto using a bracket 32, to provide additional support for the cross beam when one or more pallets is placed on the cross member. In using cross beams of reduced material and strength, such support is necessary and would otherwise not be provided by the upright frame assemblies alone.

The upright supports 30 are preferably attached to the beams 24 at the halfway point between the outer upright frame 26 and the centre upright frame 28. As the racking system 20 is designed to accommodate two pallets in this space, the upright support 30 therefore does not interfere with the loading of the pallets, and once loaded, there is a pallet on either side of the upright support 30.

The upright supports therefore reinforce the beams 24 which use much less steel than regular beams and allow pallets of the same weight to be loaded onto the racking system 20 without compromising the integrity of the beams. The upright supports 30 are therefore far more cost effective than use of additional frame assemblies in a “Pushback” and “Flowthrough” system. The upright supports 30 also allow the use of reduced capacity beams, typically a beam with a steel thickness of 9 mm as opposed to the standard 12 mm, yet still hold the same pallet weight.

Referring to FIGS. 2-4, there is illustrated a bracket 32 according to a first embodiment of the invention which provides the support for the cross beam 24 and attaches to the upright supports 30. The bracket 32 includes a main perpendicular body portion 33 having two angled apertures 34 through a front face thereof, the apertures being spaced a short distance from the vertical ends of the front face. Extending downwardly from these apertures on the reverse side of the front face are lugs (not shown) which are adapted to engage with corresponding apertures on the additional upright support 30. The bracket is therefore locked into place against the upright support 30. The upright support apertures, also mentioned earlier in this description, are not described in detail as such apertures and their means of engagement with corresponding lugs (not shown) is well known in the art.

A similar bracket is also used to secure the cross beams 24 at their ends to the upright frame assemblies 26 and 28. Thus, the same type of brackets 32 can be used for the upright frame assemblies 26 and 28 and upright supports 30. While it is a preferred embodiment of the invention that the bracket 32 be the same as that which is used to secure the upright frame assemblies 26 and 28, it is to be understood that the bracket can be manufactured separately if desired.

The bracket 32 further includes two L-shaped platforms 36 and 38 which when assembled, as described below, provide a means of supporting a cross beam. The lower L-shaped platform 36 is preferably welded to the front face of the main body 33, and preferably some 115 mm from the top of the front face as seen in FIG. 2. The length of the platform 36 is greater than that of the bracket 32 and thus the platform 36 extends outwardly from the bracket, preferably by some 47 mm. The lower L-shaped platform 36 also contains two circular apertures 40, preferably some 21 mm from either end of the platform. The upper L-shaped platform 38 also includes two apertures 42 in a corresponding and co-aligned position.

It is to be understood that these measurements are in accordance with one embodiment of the invention, and are not intended to be limiting. Furthermore, as will become apparent, the invention is not intended to be limited to the use of bracket 32 including two platforms. For example, the platforms need not be L-shaped and could indeed be replaced with a single member for supporting the cross beam.

The upper L-shaped platform 38 is adapted to engage the lower platform as shown most clearly in the exploded view of FIG. 2, that is, such that the base of the upper platform 38 rests against the lid of the lower platform 36 creating a U-shaped pocket 44 as seen in FIG. 3. This allows the apertures 40 and 42 of both platforms to align and bolts 46 can be inserted therein to secure platform 38 to platform 36. In preference, the bolts 46 are counter-sunk and do not extend above the apertures 40 and 42.

The U-shaped pocket 44 created by the bracket 32 and platform 38 is therefore adapted for the insertion of the beam 24, with the underside of the beam 24 resting upon the base of the platform 38. The beam is then held and secured in the pocket 44 and as the pocket 44 is of a relative size to the beam 24, it does not move within the pocket 44.

The lower platform 36 therefore provides the strength and support to ensure that the beam 24 does not depress and the upper platform 38 holds the beam 24 in place so that it does not stretch outwardly or distort. The pocket 44 also holds the beam securely so that there is no rotation of the beam 24 when the pallets are pushed over it as is customary in the ‘Pushback’ and ‘Flowthrough’ racking systems.

As the upper L-shaped platform is not fixed to the bracket 32, it can be altered depending on the type of beam 24 used. If the beam 24 is of a greater height, the upper platform 38 and lower platform 36 can be attached as described above. If the beam 24 is of a lower height, a spacer (not shown) can be placed between the upper and lower platforms and bolted to the upper platform 38. This provides the additional height required to ensure that the upper platform 38 reaches the desired height to support the beam 24. Thus, the same bracket 32 and platforms 36 and 38 can be manufactured and altered as desired by the end user, rather than separate bracket and platform combinations requiring construction.

Referring now to FIG. 4, there is illustrated the desired arrangement of an additional support provided to a pallet racking system in accordance with the present invention. The cross beam 24 of reduced strength/size sits inside pocket 44 and is supported above the platforms 36 and 38 of bracket 32, which is securely attached to the upright support 30 via its main body portion 33. It has been found that the bracket 32 and additional support 30 provides the necessary reinforcement to each cross beam 24 to support the weight of two pallets stacked thereabove and on either side of the bracket.

The skilled addressee would thus realize from a reading of the first embodiment of the present invention how the system 20 and reinforcing assembly comprising the additional upright support 30 and bracket 32 effectively halve the span of a cross beam without requiring the addition of a new upright frame assembly and/or requiring the beam to be shortened. The present invention could thus have application in a number of different structural systems and not necessarily only in pallet racking systems.

FIG. 5 illustrates a pallet racking system 50 and bracket 52 therefor in accordance according with a second and preferred embodiment of the present invention. Parts of the system 50 that are considered the same or similar in function to that of the system 20 are referred to using like reference numerals.

The system 50, as embodied in this second embodiment, includes two outer upright frame assemblies 26 with no central frame assembly, although other frame configurations are indeed possible and within the scope of the present invention. Disposed between each of the two outer frame assemblies 26 is an additional vertical support 30, as per the first embodiment, with a bracket 52 engageable therewith at a desired height for providing the necessary support to the middle of the cross beam 24 for supporting two pallets there above. In this embodiment, it can be appreciated that the additional vertical supports may indeed include bracing 53 between supports spaced along the depth of the racking system, if such additional bracing is deemed necessary.

The bracket 52 of this second embodiment is shown in a number of views in FIGS. 6-8 and it can be appreciated that the bracket includes, generally, similar features to bracket 32 of the first embodiment. For example, the bracket 52 includes a main body 32 configured to be secured to the additional support 30 by known means, as well as a U-shaped pocket 54 for accepting and supporting the cross beam 24 on a base support surface 56 thereof. However, rather than include multiple connectable platforms, the bracket 52 includes a single L-shaped member 58 adapted to be secured to the main body (again by known means) and thereby form pocket 54 and a base support surface 56 using less components. In addition, the base support surface 56 includes special shaping in the form of a gentle curvature along its length and rounded ends adapted to minimize creasing (stress concentration) in the cross beam 24.

The skilled addressee would understand that when a load (a pallet) is placed on either side of the bracket, the beam will adopt a slight curvature owing to its reduced strength characteristics. Accordingly, the shape of the base support surface 56 of bracket 52 is designed correspondingly with the envisaged curvature of the cross beam to increase the abutting surface area and thus reduce stress concentration at any one point. The bracket 52 further includes an upright portion 59 for preventing movement of the beam 24 along a depth dimension of the frame relative to the support 30, two reinforcing braces 60 beneath the base support surface adapted to contact the main body 53, as well as apertures 60 in the event it is necessary to lock the cross beam to the bracket 52 using known fastening means. It is a preferred embodiment of the invention that the above elements be in accord with the above measurements but it is to be understood that any measurements can be used a required to achieve the same result.

Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in this field.

In the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprising” is used in the sense of “including”, i.e. the features specified may be associated with further features in various embodiments of the invention. 

1. A pallet racking system including: a frame assembly including a width and a depth dimension, said width dimension being defined by two outer upright frame assemblies, said frame assembly further including one or more cross beams extending horizontally between said two outer upright frame assemblies, wherein substantially aligned cross beams along the depth dimension of the racking system are adapted to support one or more pallets; and at least one additional upright support disposed on a front or rear side of a first one of said cross beams between the two outer frame assemblies, said additional upright support having at least one bracket configured to assist in supporting said first cross beam.
 2. The pallet racking system as defined in claim 1 wherein said first cross beam is of a length sufficient to accommodate two side by side and spaced apart pallets.
 3. The pallet racking system as defined in claim 2 wherein said additional upright support and associated bracket is disposed approximately halfway between said upright frame assemblies to thereby assist in supporting said first cross beam; and wherein said first cross beam is adapted to support two pallets on opposed sides of said bracket.
 4. The pallet racking system as defined in claim 1 wherein said bracket includes a main body configured to be secured to the additional upright support.
 5. The pallet racking system as defined in claim 4 wherein said bracket further includes a base support surface extending outwardly from said main body to thereby support said first cross beam.
 6. The pallet racking system as defined in claim 5 wherein said additional upright support is disposed rearwards of said first cross beam, and the base support surface extends forwardly from said main body.
 7. The pallet racking system as defined in claim 5 wherein said base support surface is horizontal.
 8. The pallet racking system as defined in claim 6 wherein said base support surface includes a curvature along its length adapted to correspond with a curvature along said first cross beam when pallets are supported on either side of said bracket.
 9. The pallet racking system as defined in claim 8 wherein said base support surface further includes rounded off edges.
 10. The pallet racking system as defined in claim 5 wherein said bracket further includes an upright support surface for preventing said first cross beam from movement along said depth dimension relative to said additional upright support.
 11. The pallet racking system as defined in claim 1 wherein said system includes a plurality of vertically spaced cross beams extending between pairs of spaced apart upright frame assemblies disposed along the depth dimension of the racking system.
 12. The pallet racking system as defined in claim 11 wherein the cross beams are substantially aligned along said depth dimension such that racked pallets are supported and moveable along the aligned cross beams.
 13. The pallet racking system as defined in claim 12 wherein the cross beams that are substantially aligned along said depth dimension form a slight angle for facilitating movement of the racked pallets by gravity along said depth dimension.
 14. A reinforcing assembly for a frame system having a frame assembly with a width and a depth dimension, said width dimension being defined by two outer upright frame assemblies, said reinforcing assembly further including one or more cross beams extending horizontally between said two outer upright frame assemblies, wherein substantially aligned cross beams along the depth dimension of the racking system are adapted to support a load, said upright support assembly including: at least one additional upright frame member disposed on a front or rear side of a first one of said cross beams between the two outer frame assemblies, said additional upright frame member having at least one bracket configured to assist in supporting said first cross beam and load.
 15. The reinforcing assembly as defined in claim 14 wherein said frame system is a pallet racking system and said load is in the form of one or more pallets.
 16. The A reinforcing assembly as defined in claim 15 wherein said first cross beam is of a length sufficient to accommodate two side by side and spaced apart pallets.
 17. The reinforcing assembly as defined in claim 16 wherein said additional upright support and associated bracket is disposed approximately halfway between said upright frame assemblies to thereby assist in supporting said first cross beam with two pallets on opposed sides of said bracket.
 18. The A reinforcing assembly as defined in claim 15 wherein said bracket includes a main body configured to be secured to the additional upright support.
 19. The reinforcing assembly as defined in claim 18 wherein said bracket further includes a base support surface extending outwardly from said main body to thereby support said first cross beam.
 20. The reinforcing assembly as defined in claim 18 wherein said additional upright support is disposed rearwards of said first cross beam, and the base support surface extends forwardly from said main body.
 21. The reinforcing assembly as defined in claim 19 wherein said base support surface is horizontal.
 22. The reinforcing assembly as defined in claim 19 wherein said base support surface includes a curvature along its length adapted to correspond with a curvature along said first cross beam when pallets are supported on either side of said bracket.
 23. The reinforcing assembly as defined in claim 22 wherein said base support surface further includes rounded off edges.
 24. The reinforcing assembly as defined in claim 19 wherein said bracket further includes an upright support surface for preventing said first cross beam from movement along said depth dimension relative to said additional upright support. 